FRP Media Insert for Radial Air Flow Reactors
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Solution Overview
Problem
Existing radial flow reactors face limitations due to the structural weakness of non-reactive media containment materials, which restricts the size of the units and decreases efficiency and increases costs, while also requiring high energy consumption and potential air leakage.
Innovation Solution
The development of corrosion-resistant fiberglass-reinforced plastic (FRP) frameworks with a 68% through-space ratio, featuring a three-layered construction including an external FRP wall, a central corrosion-resistant screen, and an internal FRP wall, allowing for larger, more efficient air remediation systems with reduced pressure drop and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-reactive media containment materials are used, then corrosion resistance is improved, but structural strength deteriorates
Solution Approach 1:
The patent employs fiberglass-reinforced plastic (FRP) composite materials for the containment structure. The FRP combines plastic matrix material with fiberglass reinforcement, achieving both corrosion resistance and structural strength. The composite structure allows the walls to be sufficiently thin (maintaining open air flow space) while still providing the necessary mechanical strength to support large-scale reactor configurations.
2Strength
If the bulk of solid portion of containment walls is increased to make walls stronger, then structural strength is improved, but open air flow space decreases
Solution Approach 1:
The FRP composite material enables thinner wall construction while maintaining structural integrity. This reduces the solid portion of the walls, thereby increasing the open air flow space between the containment walls and the media, improving air flow efficiency and productivity.
Solution Approach 2:
The containment walls are designed with a porous or open structure that allows efficient air flow. The FRP material can be configured with controlled porosity to maintain structural strength while maximizing open space for air passage, ensuring high productivity with minimal pressure drop.
3Productivity
If vertical flow of air stream is used, then pollutant removal is improved, but energy consumption increases
Solution Approach 1:
The patent inverts the conventional vertical flow approach by implementing a radial flow configuration. Air flows radially outward from the center toward the periphery of the reactor, allowing pollutant removal through the media without requiring compressors or vacuum units, thus maintaining high productivity with minimal energy consumption.
4Use of energy by stationary object
If radial flow reactors operate at ambient pressure, then energy consumption is reduced, but potential for air leakage increases
Solution Approach 1:
The FRP containment structure provides robust sealing and structural integrity at ambient pressures. The material properties and construction quality ensure reliable prevention of air leakage while maintaining the energy-efficient radial flow operation at ambient or slightly elevated pressures without requiring expensive seals or vacuum units.
Data Source
AI summary
A support framework for containing a media that is used to remediate corrosive vaporous pollutants in an air stream. The support framework is situated within a plenum and comprises two concentric open-lattice weave frameworks made from corrosion resistant fiberglass reinforced plastic “FRP”. The frameworks are of differing diameters and the media is placed into and contained within the open space formed between the inside wall of the outer framework and the outside wall of the inner framework. The open-lattice weave design allows a greater radial flow through the media per unit of time, doing so with less pressure drop and using less energy than the prior art. The use of FRP to form the framework walls allows creation of large units that are suitable for use in municipal and industrial settings, which was not possible previously.